Apparatus for treating gaseous and fluidized powder streams



Feb. 23, 1954 Q L JOHNSEN 2,669,974

APPARATUS FOR TREATING GASEOUS AND FLUIDIZED POWDER STREAMS Feb. 23, 1954 APPARATUS FOR C. l. JOHNSEN TREATING GASEOUS AND FLUIDIZED POWDER STREAMS Filed Dec. 25, 1947 8 Sheets-Sheet 2 +I? MS +7 3tlg. 3 y

Feb. 23, 1954 C. l. JOHNSEN APPARATUS FOR TREATING GASEOUS AND FLUIDIZED POWDER STREAMS Filed Dec. 23, 1947 8 Sheets-Sheet 5 Feb. 23, 1954 Q JQHNSEN 2,669,974

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APPARATUS FOR TREATING GASEOUS AND FLUIDIZED POWDER STREAMS Filed Dec. 23, 1947 8 Shee1'.s-Sheerl 5 agg. /9

IN V EN TOR.

Camila/w IMM/m Feb. 23, 1954 c'. l. JoHNsEN 2,669,974

APPARATUS FOR TREATING GASEOUS AND FLUIDIZED POWDER STREAMS Filed Deo. 25, 1947 8 sheets-sheets ooo JAL l 12| t E T v2.7 L H4 f' mi m 5sc.2 J?" 3q.z3 n '29 o z zo lo%a\ 27 O20 o v rv\ H5 H9 :nali-2l fw |29 |27 OOO OO m o ns o?? 37 22 00 n* )09 H25: 'L3

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APPARATUS FOR TREATING GASEOUS AND FLUIDIZED POWDER STREAMS Filed DeC. 25, 1947 8 Sheets-Sheet '7 l INVENTOR. 2kg. Z4

Feb. 23, 1954 c. l. JoHNsEN 2,669,974

APPARATUS FOR TREATING GASEOUS AND FLUIDIZED POWDER STREAMS Filed Deopz 1947 s sheets-sheet 8 I aos y f l 1m m i 202 ,-r- 204 E 5 r Zoo g s 0'0"'0( vv A* v L 1v ,l

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INVENTOR.

Patented Feb. 23, 1954 UNITED STATES PATENT` OFFICE APPARATUS FOR TREATING GASEOUS AND FLUIDIZED POWDER STREAMS Carsten Ingeman Johnson, Floral Park, N. Y.

Application December 23, 1947, Serial No. 7 93,396 16 Claims. (Cl. 122-4) My invention relates to the treatment of gases and of gaseous streams into which have been entrained small particles of solids or liquids and to the apparatus for such treatment.

There are a number of industries in which my invention is of great value and a number of modes of employment in which it can be used effectively. Among these uses are the treatment of industrial gases for the removal of smoke and ashes, the separation of isotopes through the .use of selective diiusion barriers and the production of water gas or producer gas from pulverized ',coal. Many other uses will occur to those skilled in pertinent arts.

In all of the above industries an darts dii culties have been encountered in providing means to sustain the movement of gaseous streams, as well as in efciently transferring heat to and separating solids from these streams.

Vlt is for such problems that my invention provides a solution. l

Characteristic of my novel method is a treatment of gaseous streams which comprises leading the gaseous or fluidized powder stream through a series of units, each unit being a heated chamber through which the stream is caused to pass upwardly and a cooler chamber, through which cooler chamber the stream is caused to iiow downwardly.

In this way, by the arrangement of a heated upward channel followed by a cooler downward lclosure containing my novel apparatus when used to make water gas, the view showing merely the sectional or cutting planes on which Figs. 2 to 1'7 are taken.

Figure 2 is a horizontal sectional View taken near the top of the apparatus on the line 2-2 of Fig. l showing preheated air ducts, part of the path of the newly made fuel gas, the air preheater unit, and the fueland air entry points.

Figure 3 is a horizontal sectional view taken ad below Fig. 2 on the line 3 3 of Fig. 1 showing the upper parts of the apparatus.

Figure 4 is a horizontal sectional View taken near the bottom oi the enclosure on line --t of Fig. l showing the hoppers for collecting precipitated particles from the chambers of the processing zone.

Figure 5 is a horizontal sectional view taken a little below Fig. 4 on the line 5 5 of Fig. 1 showing the hoppers for collecting precipitated particles from elements of heating zone.

Figure 6 is a vertical sectional view taken on the line SME oi Fig. l showing portions of the path of combustion gases in the heating zone, the mixing chamber, the preheated air passages.

Figure 7 is a vertical sectional view taken at right angles to Fig. 6 on the line '-l of Fig. 1 showing additional parts of the heating zone.

Figure 8 is a vertical sectional view taken on a plane parallel to Fig. 6 on the line 8-8 of Fig. l showing additional elements of the heating and processing zones.

Figure 9 is a vertical sectional view taken on a vplane parallel to Fig. 7 on the line 9 4? of Fig. l showing further elements of the heating and processing zones as well as the mixing chamber.

Figure 10 is a vertical sectional view taken 'on a plane parallel to Figs. 6 and 8 on the line Iii-Hi of Fig. l showing essential elements of the reaction heat section.

Figure ll is an enlarged View in section of a gas generator tube.

Figure 12 is a View in cross-section of the tube shown by Fig. 11, the section being taken on the line l2-I2 of Fig. 11.

Figure 13 is an enlarged view of a typical ver- 'tical section showing a preferred wall construcelements of both the processing and heating zones as well as a fragmental view of the preheated air passage 3l.

Figure 16 is a vertical sectional view taken in a plane parallel to Fig. 14 on the line Iii-i6 showing elements of both the processing and 'heating zones.

l Figure 17 is a vertical sectional view taken in a plane parallel to Fig. on the line ll-H showing additional elements of both processing and heating zones including primary combustion chamber.

Figure 18 is a key plan or diagram showing how Various units of a gas turbine installation may be advantageously combined with this embodimen't' o therinvention andelements ot'a steam boiler.

Figure 19 is an isometric view of a simpliiied gas generator, showing the general relation .of the heating tubes and chambers oflhellocessing.. zone.

Figure 20 is a horizontal sectional View cfa Water gas producer counterflow taken on line 25.--2B,.o1 Fig,.,2 l,show,- ing in plan the upper ports, the connecting contiguous ports, the partitioned tube nestportionsL and the directions of flow. This View corresponds approxirnately'to Fig. `3 taken on line-3 3 of` Fig, 1, but is adapted-to.illustra-te-counterflow operation-.-

Figure 21 is aver-tical sectional View. of a counteriiow apparatustaken; on -line 2 l-2 of Eig. 29 showingpathtraveled by products ofA combustion or other heated gases inyapartof the heatingzcne..

Figure 22 .is afyerticalfsection of the-:counterow-aapparatusitaken cnn-line 22-22 of Fig. 20 showingga-part .of,y the path traveled by gases undergpnggprocessing in a f counterflow `apparatus aswell as the-downward ducts |21 and 129.

-Figure23 is .a-'verticalsectional view taken on linef-,f--Zav` of Fig, ,20 showing elements of the processingfandrheating; zcnesincluding a section through theinitial mixing Chamber.

Figure- 24 ,Ais1 af flow diagram of :my :invention as used in. making water gas.'

Figuref25; isfa diagrammatic sectional view of therlnventionn aSUSed With alsteam- .boiler wherein one section is heated by, boiler combustion chamber gases :and another section is heated Eby thosegases "after they are-@mixed with additional hetfgases.` from mygprocess and apparatus as --described vlin connectiorr'wth the precedingV figures.

The method for the generation of fuel gas herein disclosed contemplates .-a :system having two separate streams-ofiflow'which for-convenience-.Will be :called: .thctheating zone orV enclosure and the processing zonefavor: enclosure.y In the .heatingzonehpowderedfcoal and air iareburned. In the processing zone powderedbemand-steam, :preheated .toafsuitable temperature;- v.are :rea-ctedi to, form..-.-water f gas.l The: hot gases Vresulting from combustion in the heating zone are used, first: to iraise. the-pp-wde1-edoor-Ll.v and steam. of -the .processingffzone .to thefoptimum temperature 4for the water .gas rreaction', and then, tofprovide at this high temperature the heat of reaction nec- ,essary f or the: conversion Aof vthese processing k,zone 1 zone. Icall .thefreaction-heat section, because-the heat generated' in this por-tion goes primarilytoward. adding l.to ythe ingredientsthat .are.wit'hin theghot processing zone the heat of reactiondemanded by-theendothermicwater gas .con-version. This reaction-heat section includes in Fig.

yand air-'are led into thefchambertfof the heat- `ing zone.: Herecthey burn toficarbon'tmoncxide which is led out through a set of parallel tubes 28 (the details of which are hereinafter set forth in detail).v into-asecond chamber 30, where the oxidationziszcompleted with the production of carbon dioxide. This CO2 in turn is led through another .set .of-'tubes 40 to the chamber 4I.

Meanwhile other powdered coal and preheated air'haveb'eenl introduced into a pair of duplicate `chambers 55 and 55a where they combine to form carbon monoxide (similarly to chamber 26). From (chambers. 55 .and 55a the monoxide gases move separately.intoanother. pair of chambers 6| y.and Bia .wherein additional preheated 1 air :'is introducedand .thecarbon monoxide is in turn burned` to carbon dioxide, aswas done in chamber .30.. This hot .carbon dioxide passes through ducts vv62 and 612a-into. chambersfll and. 43 where it joins theCQz .gas which has concurrently been produced lin thesensibleheat section, as described in. the ,.precedingparagrlih;

The combined.. ,gases chamberV 4| move through Aa series ofparallel tubes 4.21to-thechamber-.43 and -thence through anothersmil'ar series of tubes 44 to the chamber 63. `From 1thereafter surrendering, most .of .theirremaininghea't to a steam boiler,- they arel allowed Ito. pass to the atmosphere.

Thus ,in .the-heating zone, hot gases from two diierent sources.are directed l,through a series of tubes .and .chambers tol nal disposal. It remains to describe the path through which the processinggzone ingredients Aare led, `enabling them 'to ab'sorb theheat fromthe heating zone In..theprocessingzone va mixture lo steam, powderedcea'lrand.recycled 'water gas (this recyeled ,gas 'beine obtained :as hereinafter described." is mixed thoroughly in chamberl and then ,made tapass. twice amongthe tubes .Moi the heating zone. The structure by which "this is accemplished is hereinafter described in detail. Havingmade its' two passes through `the tubes di), theprocessing zone: ingredients are now'at the proper temperature for the-'waterAgasreaction to occur: They-moveto thetubes 52 vof the heating-zone and make two passes -among them movingtherefrom tofcontact thetubes V413. In pass- 'ing amongthese groups ofA tubes 12:2 land M. which.

.of @tubes -Landattendant .processing zone passages .is shown-,inFigi 19,.y

In that gure, diagrammatically audvmerely for .fthefplllpcsefof illustratiom. is Yehem/r1 a V.typical ,section-'ofi thesystem Iof .chambers and passages.

Thesefhavebeen somewhat expanded and the wall ,thicknss :minimized morder :to more `clearly visualize thegeneral; l.relation betweenthe `-heating .tubes-and..the .various-.ducts an -encldsures AS will' hereinafter more fully' appear primed reference numeral-s used in Fig. 19 correspond generally with similar numerals in other figures.

In this structure,y there is an initial vertical mixing chamber 12' connected horizontally at its lower end (as at llc in Fig. 19) to the lower part of another vertical chamber 11', which extends upward, enclosing within its walls a section of horizontal heating tubes 46. At its upper end the chamber t?" is connected to the top of a second chamber 'i9' iby a horizontal passage 18 perpendicular to the direction of the tubes All. Chamber 9 extends verticallyr downward for a short distance, runs in a downwardly oblique direction parallel to the axes of the tubes for an additional short distance and then runs vertically downward until it reaches the level of the bottom of horizontal chamber 71e. Here it is connected horizontally at its bottom to a chamber 3l by a chamber 8d identical with and parallel to llc. Chamber 3|' extends upward to encompass a second portion or" the tubes ed', and is joined at its top by the horizontal duct-to 'the chamber 32' which is similar in shape and parallel to chamber i9. Chamber 82' is connected horizontally at its bottom to chamber 83'. Chamber 253 extending upwardly encompasses a third portion of the tubes itil and is joined through chamber 8d' to chamber 55 similar and parallel to chambers 82. and 79'.

Chamber 85 is connected horizontally at its u bottom to the vertical chamber 86. Chamber 86', extending upward parallel to il', 3i' and 83', terminates at the port 95.

In Fig. 19, a mixing of the powdered coal, steam and recycled gas takes place in space l2', and the ingredients flow up through chamber 'il' passing amc-ng the heated tubes ll which are disposed horizontally through chamber 'i7'. Clearing these tubes, the stream moves through chamber 'Z8' and down chamber 79', which is unheated, and then horizontally and rearwardly through chamber 8 to emerge in chamber 8l. In chamber 8l' the gases rise and again contact the hot tubes dil. This process is repeated through the subsequent passages and the gaseous product finally emerges from port d5'. The tubes 4G traverse chamber 8| and 83 in the same manner as chamber 'll' to which 3l and 83' are similar.

The illustration in Fig. 19 is presented to give a general or diagrammatic picture of my method of handling a suspended powder or gaseous stream. A more complete description follows:

Describing my invention more fully, the novel apparatus when used for the making of fuel gas from carbonaceous products and steam should preferably be in an enclosure built largely of materials capable of retaining their shape and strength at relatively high temperatures. Tubes will be made from refractories, heat resisting alloys or a combination of both. Mechanical feeders, injectors, ejectors and similar devices with minor modifications are available in the open market. ln general, the construction of the apparatus and the number of relative size tubes and other elements given for descriptive and illustrative purposes, may be varied by those skilled in the art to conform to generally accepted furnace practice.

Referring to Figs. 1 17, as heretofore stated, my apparatus may in a broad sense be divided into two zones. The rst or heating zone, includes two sections, a sensible heat section and a reaction heat section. The sensible heating Section comprises primary and secondary combustion chambers 26 and 3% (Fig. 6) and a series of the tube nests such as 40 and chambers such as 4| (Fig. 7) which lead eventually to a mixing chamber 63. The reaction heat section comprises t-wo primary combustion chambers 55 and 55a (Fig. 10), two secondary combustion chambers 6I and 5m (Fig. 10) and ducts t2 and,2a'(Fig. 10) which ducts being the hot gases producedin 55, 55a and l, (ila to chambers All and Il? (Figt 7) where they mix with the hot gases from the sensible heat section. From chamber dl on through to mixing chamber S3. (Fig. 9), the sensible heat and the reaction heat sections are one and the same.

The second or processing zone comprises initial mixing chamber 12 (Fig. 14) and a system of chambers such as 17 and 78 (Fig. 14) which lead the products to be processed among the hottubes of the tube nests of the heating zone.

The function of the heating zone is to provide the correct temperature in the het chambers lof the processing zone and to supply heat for the chemical reactions which occur. rrhe function of the processing zone is to provide a means whereby reactants can be subjected to heat, their motion aided by convection and any undesirable solids separated from them.

HEATING ZONE (a) Sensible heat section For the supply of heat for the heating zone, fuel, preferably pulverized coal, is delivered in predetermined quantities from a pulverizer and coal storage bin to the burnery 25 shown in Figs. 2 and 17. Preheated air enters the combustion chamber 26 through duct 2l connecting with the air preheater 63 through a horizontal duct l0 as shown variously in Figs. 2, 3, 6 and 17. In this chamber 26 combustion will be largely incomplete to give principally carbon monoxide.

Additional heat may also be released, if desired, in space 26 shown in Figs. 3, 6 and 17 by burning therein such incidental coal particles as may be discharged into it from processing zone collecting hoppers as hereinafter described. Also unconsumed carbon discharged into chamber 26 from burning out operations as hereinafterdescribed may be employed in this fashion.

The products of primary combustion produced in space 26 move through tubes 28 into space 30 shown in Fig. 6 (see also Figs. 2 and 17). Additional air to bring about complete secondary combustion of these products in space 3l) to give carbon dioxide, is supplied from air preheater 68. This preheated air is led through the horizontal duct 10, down a vertical duct 3i (Fig. l5) where it cools the walls between 3| and adjacent ducts and absorbs heat in passing. It then runs through the horizontal leg or an L-shaped duct 32 (Figs. 5, 6) and rises through the vertical leg around a portion o the heated tubes 28, therein absorbing heat. A wall 36 between the duct 32 and chamber 30 supports the tubes 28 at their mid-portion. The gas rises over the top of the wall 3S and then moves downward among a second portion of the tubes 28, again absorbing heat and nally discharging into the secondary combustion chamber 30. This discharge is accomplished through the triangular ports 33 in the wall 35 of the chamber Sil. The ports are formed by fitting the square tubes 28 into the somewhat larger square apertures in the wall 35 so that the cross-sectional diagonals of the tubes are perpendicular to the sides of the apertures as best shown in 15. The wall 35 thus supports one andi iof ttubes 28 f the other.: endsfzozthese i tubes; passizthr'ough landv sareesupportedbythe; wall: 34; cti-chambers 26,. .in .suchmann'er that .the gases-I from=chamber 261may. pass .through the tubes to. chamber 30. The 'iwall Saibetween chambersut. and. 3d-.iis .l otherwise imperforate.

VBy properly .proportioningxfuel, air.,v heating sura'eeswand combustion space volumes,u..there willlbe ,produced insspa'ce 3o :produ-cts; orv poom.- bustion, :at `la.`temporature ulevel. :well 'ini excess of that ,demanded :by the water: .gas equilibriasaud reaction'. rate considerations.

r-As previously 'indicated the gases fromfch'amber 30 pass successively into chambers='i.,'3an`d G3i througli1 tube-nests iigf Maand.. .134;

`The=tubes wither tube inests-vtt; ylli.''iandftli areA similarstructure.; In each nest'thetubesformit .extend from an' end partition 'or Wall 'ot the chamber (either .730, 14| `for .d3 l 1 to: the opposite partition .or'walli of fthe next :succeedingechaniber 45t., 43-or.63as:the"case2maybe; These nestsafnd chambers are shown `inFgs; 3.1:and- .64); The tubes themselves are parallel and'are:stackedfand. spacedtoiforma series of passages between their centrali po'rtonsfas shown in-Fig; v13:1

As showin .thevside-` rcws'fotftubesufof the tube nest may be built into the fwalls :'a'ndf partitions so that each such.tube vwillexpose two heated faces. These are substantially at the saine temperature levell 'f as any 'on'e'oiVV the 'interior tube su1;.taces.`l4 l Thus,- thefgasesfpass between heated surfacesat approximatelygthe same temperature, assdistinguished lfromeontact with -a heatedsurfacetat. oneaside. and-a' cooler suri'aceon the other;

Thet longitudnalaxes fof. the tubes are pretore ablyginclined .downWardly ,-in ,the d-irection'oy how of .theal products ,of combustion; passing through them ;to .discouragethe/formation. .ofV depositssoi` coal or ash ontheir. inner surfaces.'Y

The-junctions. where tubes of nests M'L- f3.2 ,ended meet withf the Wallsare made-as. tight .as possible. to.. preventfleakage from lthe processingy zone tof thesheatinggzone or `vice versa.

- Satis'iactorygmaterials from which tomakefthe. individualv tubes are vvretractories. Thesemay be basedronrsil-icon carbide,.aluininunroxideor alu,- minumL silicate; or molybdenum. alloys or-.rother heat resistant. metals maybe used. Aftypeoi. tube construction. ,which -.may-be r,used. .is that shown: nFigs.' 11;and..12, which'. illustrate a compound. tubeihaving azlining 3l. ofthe refractorymaterials mentioned. with.. an. outer `casing V38..made.=o;f; an; alloyhaving .high temperature resisting: qualities. such as .the molybdonunrrV aloys .i above .mentipnedl` The VIusel of refractorycollarsf at Wall-junctions. will likewise improve strength, tightness andv heat.

conductivity. y

tlfie-heating@A zone, under. thezinfluencepisuction'iromcstack draft orfinduced draft fan (not:.showm,- Athe products. of combustion-are. caused.' to.,.-p ass from. chamber: 30 throughtubes. dnl-.land-.ginto chambers! (Eigg'); thenathrough. tubes-.4L to.,chamber 43 (Eig, 8) and finally through tubes de .(Fig...9) -into-.themixing chaine ber,.63.f. The-:passage :of thefhot-.gases...throughv these.. tubes will heat .the -tubewalls .and conse..A quently theprocessing zone inwhiohithesevtubes.- are.- placed. When-.xthe 4'quantitiesot...heat.supe plies are lsuiicient and the4 temperature -.-levels.. arci-Tat T.the highvlevel reduirec'l` gfor gasification,.- the. proper. .conditions .-for .making `fuel ,gas `,will be. presentin theprocessingzonm. y K y WThile .it is possible to. supplyAv all the heat needed. for. the entire water.. gas. reaction' from fr tical ducts 58, 58a. (see Rigs. 5, 7fand8).

gli

thefzburning of coal in thezsensiblesheatingyseog-- tion of Lthe'heating.. zone, ,i. 'e'.a'2 6&4 I., suchfmoda: of operationwould irequire air-largefnand rinconvenient :reaction chamber; also the itemperature: dieren-tials:fwouldaebe :great so that .moresheatf wouldbe .transferredrinitially than. is .preferable` Therefore-:it is;A preerredetozfuse thecrst par-.19* of 1'. the :heatngfzone from: chamberv 2 6 through. chamber .14| las described; toy boost the temperas and then: to: use-a new# combustion` chamber and. freshifuel for' the :purpose of .transerringiat ...that temperature level therheat of reaction. demanded. by the z endothermie .Water ,'g'asfconversion;

v(b) Reactionheat sectionV` This v.additional heat. transfer is; accomplished as follows: Fuel,preferably.,pulverized coalwis delivered inpredetermined. quantities.froml.a.pulverizer :and-coal storage bin v(not shown) ,'-toone or both` of the burnersl 54, 54a shown in Figs.A 2, 10, lzand 17 dischargingthefuel intopar-A allel.- duplicate :primary combustion. chambers J55',- 55a., The burners are of conventional construe-- tion,:and,may be of the sortcommonly used 1in steam .-boilers, and. having'v compressedair or. steam to compel the oW.. Air'for primary,--com.y bustion .originates f in` air preheater 68 1 moving.v through. the .horizontal duct 19 to individual verttical;duets.5i,.5ta shown.\in,-1"igsu2 and l0.; The products l of primary combustion more dow-nthrough chambers 55 and :-55a,. through. .the sec? ondary duplicate combustionV xchambers s SI ,-8 le;v

Air for secondaryl combustion alsoicomes from f therpreheater., iiSfandgpasses'through;.the duet.

1) (Fig. 2) tovertical,passage'3i--, through .which it moves downwardly to horizontalducts 51, 51aI which vbranch in Ydifferent directions as illus.; trated in Fig.,5 and connectwith duplicate-ver-A From. the'top of ver-tical ducts 58, athehigh .tem-. perature airv passes lthrough duplicate-horizons. tal ductsfifga (seeFig. 10) to duplicatelvertical ducts 60, aand through them downwardly. The duets .60a attheirzbottom ends lhave .short lateral extensions connecting with the secondary combustion chambers-tl', Sla. Here -high tern. perature carbon dioxide .=isY .produced-and dis. charged through duplicate ports 6.2 GZminto. heating zonespaces dl. orz43, addingftofthe-.total quanti-ty .of :heat therein The duplicate combustion chambers 6 I S la, need not `befoperated-inparallel but leach maybe operatedpalone.

The ,numbervof tubesand hencetheftotal cross sectionalarea of eachof -the tube nests.-28,- ,40; 4'2 andddshownfin Figs. 3,-6,l 7, Sand 9 increases. as-onelproceeds .fromentrance to exit of thepapgi paratus. lSuch an arrangementserves to coml pensatefor the increasedvolumes caused by thev addition of' hot-.gases from the Vreactionheat section tothe `main -streampf the-heating zonei. the. object vbeingto maintain'velocitiesfot flow, throughall the tubes vsubstantially constant.v

Similarly, the volumes .ofeach of-thelchambers` 3i), M, 43 andes .shownin Figs. 3 .and 6.-?9. are .successively .greater towardthe exit... Such increased.,.volumeswvillbe suiiently large toV leave a substantial margin over .and above that requireddue .to the hot gases from the. reaction of ow because such action causes and facilitates precipitation of suspended ash particles. These ash particles will collect in hoppers 64 at the bottoms of the chambers. When it is desired to remove this ash, the gate valves 6l are opened and simultaneously steam is introduced through ejectors 55 (see Figs. i7 and 5). The ash is caught by the velocity steam and carried through the tubes 63 into the space e3, whence it can be drained and discarded.

Pheheated air for the heating zone combusm tion originates in heat exchanger 53 shown in outline on Fig. 2. The heat is supplied by newly formed fuel gas made as described below. The cold air for heat exchanger t8, if it is so desired, may be drawn through spaces t9 shown in Figs. 6-10 and 14-1'7 thus cooling the top surfaces of the apparatus. After absorbing heat from heat exchanger 68, the air at elevated temperature enters the apparatus through horizontal duct l@ shown in Figs. 2, 6 8, lll-16 and is distributed to burners similar to 54, e411. as shown in Fig. 2, and down through vertical duct 3l as shown in Figs. 2-5 to passages leading to secondary combustion spaces 3! and fil shown in Figs. 3 and f 5-9. The details of construction of heat exchanger 68 are not a part of this invention.

PROCESSING ZONE The processing zone comprises all those spaces of the gas generator in which the fuel gas in gredients circulate and are processed to form substantially ash free fuel gas.

The fuel gas ingredients, consisting of a properly proportioned mixture, according to usual standards, of pulverized coal and steam, are fed into the initial mixing chamber 12 shown in Figs. 2, 3 and 14 and are intimately mixed therein. The feeding device for coal may be a screw conveyor and for the steam may be a regulatingand measuring valve of standard construction. The nely divided coal and the steam are discharged into the initial mixing chamber l2. The details of construction of coal and steam measuring denest (Fig. 7) Where it is again caught on rising convection currents between the heated tubes. Upon reaching the horizontal space 3l at the top of the nest, the mixture moves horizontally into the next part of the system, where it is again cooled by the cooler passage walls and drops down chamber 82 (Fig. 15). It then moves up the vertical chamber 83 through a section of tube nest 42 (Figs. 8, 15), rises among these hot tubes and is carried through horizontal duct 84 to vertical chamber 85 (Figs. 3, 8, 15, 16). It moves down and forward in chamber 85 to the horizontal leg of L-shaped chamber 86 (see Figs. 15, 16, 8) and up the vertical leg of chamber Bt among the spaces between the tubes of tube nest 42 to horizontal duct 81 shown in Fig. 8. From here it moves down through the vertical chamber 88 to chamber 83 rising through its vertical leg among a section of tubes 44, up to horizontal duct tu shown in Figs. and 16. Thence it proceeds down vertical chamber al (Fig. 17) to the horizontal leg of an L-shaped chamber 92. It proceeds up the vertical leg of chamber 82 through a portion of tube nest 4 as shown in Figs. 9 and 3 moving up among the second section of tubes 44 to passage 93; and from passage 93 it goes to preheater 94,.shown in Fig. 2.

These successive steps among heated tubes and cooler following chambers may be repeated as many times as desired. A continuous circuitous path is thus provided in which initial heating, gasiiication and ash precipitation is eiected.

Ash precipitation Ash representing inert elements of the fuel is formed as a residue from the above gas reaction and travels along with the newly made fuel gas and unprocessed ingredients. Much of this ash is progressively precipitated, collected and .if ejected.

vices or coal pulverizers are not parts of this invention.

To aid intimate mixing as well as movement of ingredients a portion of recycled product gas may be injected along with ingredients through a valve 'I5 (Fig. 14). The speed of 'flow of this recirculating gas portion provides an effective means for initiating and controlling the speed of flow of the entire contents of the processing zone as the reactants move from entranceto exit.

',Ihe fuel gas ingredients pass downward in space l2 under the influence of the steam -jet and the recycle current, moving into space ll shown in Figs. 7 and 14. In this space the ingredients are caught on rising convection currents gener ated in the spaces between the heated tubes of tube nest 4D and move around and in among these tubes coming in intimate contact with their wall surfaces, thus absorbing heat. The rise in temperature of the mixture is extremely rapid because of the high temperature gradient between the mixture and tube walls. On reaching space 18 (Fig. 14) at the top of the tube nest, the mixture moves horizontally into chamber 79. Here the mixture is cooled and falls, moving along the inclined path of chamber 'lll (Fig. l5) to chamber (see Figs. 7 and 15 and compare Fig. 19).V The stream travels through the horizontal portion or leg of chamber 3d and up'the vertical portion or leg through the next following section of tube Although the pulverized coal for processing will generally be too finely divided to be separated from suspension as described above, incidental coarse or combinations of coagulated rines may be thrown out of suspension in the apparatus already described by the combined actionv of gravity, reduced speed of flow and curvature of path before their gasification is effected. In that event they will be collected along with the precipitated ash in hoppers 33 shown in Figs. 4 and 14-17.

To prevent the loss of fuel value from such separated coal particles, they are collected and introduced into the heating zone where they are f completely burned. To accomplish this, the hoppers 98 are provided with gate valves il When these are'opened the precipitated particles drop and are caught by the swiftly moving steam lintroduced through the ejectors Mlil and are carried through tubes S9 to the initial mixing chamber 2E of the heating zone. Here the coal will burn while ash may be carried along by combustion gases for later precipitation.

Separation of #y ash In addition to the above, consideration must bc given to the nely divided or excessively lightm weight fly ash which resists precipitation in the manner described above. Such lightweight material can be largely removed from suspension by one or more oil sprays m3 (Figs. 2, 16, 17) placed in the path of the moving stream of processing cone contents. This serves also as a means for furnishing carburetting hydrocarbons.

vThe carburetting oil for the oil spray is fed into l 1 the' duct-(9 l' fromu a L`fueloilsource (not shown-)- tli'rugh3*"vaivecl` pipes 'r i "21=f"dis'charging in f either anjatomized or 'vaporizedfornfii'fL Witl'gproperly arranged direction" of l iio'w` *and mannen-oft 'dis-` tributing `the' oil dischargefa'fscreennis provid-3d bythe-spray as shown Ithrough whichv tlieffiiyl ashila'den fuelgas must pass to thfeX-it Much of tl'i'e 'lightweightash will becaughtin"this'oil screerrand leither deposited-'on the' ductl surfaces or precipitated and' collected:asy coagulatdcoal particles in hopper`` :28L under duct 9| andspace 92shcwnv in Figs; 4, 9 Vandfl, 'th`en"ejectedthrough val-Ve -`'l 01 and tube i9 9 to` space" 2 6 "shownir ini Figfs; 4 'andA 17` for recovery ofi-any available"T fuel-.value The last'partitio'ned f' portion Oftube' -nestf '46 shown in Figs-2, 3A and@ serves; if itissd'desired", asa means for Athe?superhating of` `"the 'car-V burettedl-fuelgas' fixingA same-to'f'ay stablegashav-j ingjsubs'tantially permane-ntv` characteristics; r, Tlie carburettngV and super-heating feature-described above is optional; my-'inventiondelivering; iffdl sired; uncarburettedueiv gas, ther fiyasli being partialljfremovedfrin mec-hanicalfly operateddu'sft collector 9'! 'showrrin 'outlineron Tleffcom struction 1 details?- of 'Y this.' dust coliector irare mot 1 partofmy-invention;

Clelinirigy` When vas'. a resu1tfo carburettingpr fronrzthe useffof "certain: grades and; qualities ofrrcoaigfzthe coal; particlesc-themselves?l ori-their; derivatives tad-i herevf-tofand buildfupgdeposits on; ther-processing zone surfaces Which.would intime reduce the efiiciency of the apparatus, it is not necessary to scrape orremployoth'er imechanicalumethods"for tubes;

Instead-,r coaltnvor .theaideposits:zthexnseltzes;,or both aro-"burned iin' nth'e. :processing: zones vr cir1 cuitous path, Valved inlet ducts for air lMfshown in Figs.z2,14;:16--and17furnishing 'the vnecessary air sforxfcombustion; 'and'- additional: fuel if neces-f' sarybeing ;suppliedbyf,-the coahfeedingfzfdevice 13..shown iii-:Fig: 14:- Valyed'finle't' maya-also be`^ used- 'for f the admission zof: air: D.uringnormal fuel-:gasa` generatingoperations-valtrexl Mffare closed.v`v

The'-fproducts-.fof incompletoscombustion-AproJ duced as a :result of burning-rout?'operationszare disposed: 'of without lesstof atheirr'caloriiic-i value I ber l2. This isaccompli'shed'by'leading the hot t newly producedfr gas from Avertical :channbenl 92 (FgQf'lthrough theh'orizorrtakliuct 93 .i-(Fig.y 2)? intothe spiralopassage 941e( Fijo.,Y 14) 4wliicliis-:fltted around the conical 'section-fof: tlieainitialxmixing chambeiffZ'.; This `vspirali. :passage fllfmay'be for-med. by a wall 94a? which', spirals downwardly frcmzthe entrance. at thetop', around..the. outside oftlie conical; upper partici-:th mixingxchamber 12. As ther'i'ictfgasesrswirlfthroughzstlraapassage alf'steamand recycle -gasenteifiii'gfchmhr' T2il` Cnsiderablequantitiescflieat-lwitbitransf ferredftliiougli-ltlielfwalls'l of fchamber 112? toi-rthev fuel gas4` ingredients, ftlius eicting Aa riseV iin-their temperature ata point -in the process'uwher'e'sucli arise isl mostfuseful.

' Frimrthe spiral-passage 94, the fuelfgas'moves upthfe` vertica'hduct 95 (Fig. 14:)l vand, throughthf l1'orizbntalcilu'cirSliga f2') to the heat `'exchanger 68 (Fig. 2) Where-iti'smsed topreheat'airdriuse in r'thefcornlnistionchambers-'of the heating-zone. Trecapitulate; there will is'suezffromsthe .two principal f partsl off." thef ialszparatusf.:.two-fgaseous streamsdiiferingin 'c-:haracter-'sv 1." From fthe .heatingiszonretthere Ewill issuefa continuous f iiow; of rprcductslcf fcombustionz from thertubesfof A"t1'1be1nest' lilhdischarging, intol miic#z ing.,'chamberf63 'as shown inFi'gs. v3 and;` temperature 4levelf-oif theseuffhoivgasesziis fthe neighborhood:foi-1th #temperatureiat whichthe fergasereaction talresplacexf 2;?Fro`m .theproc'essing zonev therezrfwilliissueia continuousfiow :of'htffuelw'gas:coming direc-dy from thefheaic'exchan'gerei'orirom waived ,tube l'i'conne'ctediwithtliiash separatorr.' 'I'hesnuantitiesotsensibl'fheairmarriekkoutioi the apparatus;asiziabovegrepresent'a substantial portion of theetotalYheatwexpenditure, Therefore, the degree of hatrecovery eiected from tleseetwowheatsources fiss a wery'reaif measure Aof the `thermal eiiiciency-fand commerciaux/allie oi this'in?entiifr:Y

THE STEAM BOILIEIYPFIJCOIVlBlNill'llflilfil Fig. 25 shoWs-fanzarrangementrwherebwthe'hot products :offcombustioir issungf'froniftheiheating zone' .of my. :apparatusinambe futilizedxinfcoops eration/witha-=standard:steamiboiler instaglatiom thus saving ,-11r1uch-..oi:thediea-tv wlmicliiwrouici-iother?7 wise'be-wasted. i:

The rinstallation showniin "Elige` 25 isixiesigned to'itake- `the hot gases. generated rinia' ,steam boiler combustion chamber-and aftemallowing ,them-to passethrougheonesection cfrthel boilerotulces.-t to direct then'i. intowaemixingechamberewhere they can be thoroughly blended with the higlaenftemf; perature vgasescomi-ng frcmfthe fheating. zoneof my apparatus thescombined igasesithenireturn-, ing -toftheboiler complete the. ih'eatingiof thefrest of ther-boiler tubess.,

Asushcwn inliigv 25,-shotfgaseseare 4generated in..boi1er tcombustiona chamber :1M if. They.,tlj1en moreupward#V and spassfamongthe tubes i of @the superheater. M5 Thencectheyfare drawnidciw'n. duct 20| passing through port 45a into mix-ing chamber...y 63a. i Here. theymingle,rwithrvthefihot gasesuissuing from Vi,he.i',ubes of ztube Ynest 44. The combined volumeslepa'ss-.ilout 4through.port i 49o' and. .traveliup gamona. therremaindei; io th'eboiler tubes A.2 @Landi out throughy the; ,exhaust@mit.v 2 |14.; 'I'liecuantityff boilerwg'asestwhichlpassr.through superi;eaterilllrisx controlled by Naive 'Ml'fT The .newlymade 'fuel gas issuing fr'on1 .tli;v processinelone" aftenhajvingkdone its .work'of prehating'ombustion';air in 'jheatj exchanger-8 with" orlwithout treatment iri'a niecl'iancalidist separator.' '91 ""(Fi'g". 2),"mayg if "desired," bev piped directlygto ja manufactured gas plant foi-"further processing to i' a" .standard 'f manufactured 'gasa However", a j desirable 'alternative Veuse y'to which this' substantially*'fashfreoffuebgas fmay lbfout' isfftoi-Lburnlfit'tlrira gas turbin "'ins'tallatioiiralso sirowmidiagrammaticallyiinfFigisIa;i Their-filial:

which it is injected at an elevated pressure to the gas turbine combustion chamber 53 through injector 4l through fuel gas line 5|, shown also in Fig. 2. Gas compressor llt, may be bypassed as for repairs by means of valves |69 and ibi. Along with it goes compressed air from air compressor 52 driven by the turbine 5u whose rotation is effected by the expansion of gases generated in combustion chamber 53. This combustion air for the gas turbine may be preheated by placing heat exchanger i6 in mixing chamber 63. When preheating is desired valve itl closed and valve |52 is opened. Heat recovery from its exhaust may be effected by discharging same into space b3. will act on the gas turbine because mixing chamber 63 is of relatively large volume.

When gas generator, gas turbine and boiler exit and reinjection points 45 and le are arranged as integral and literconnected units as shown diagrammatically in Fig. 1S and further,

when the gas compressor 48 is provided with variable speed driving mechanism, an eirective means for the control of speed of flow of'gas generator processing zone contents is available, the variable suction eiect of the gas compressor 48 being transmitted back to the processing zone.

By the provision of means for the control of pressure and quantity of air delivered by air compressor 48 to fuel gas injector il the rate of iiovv of the fuel gas.` may be controlled within relatively wide limits. This controllable suction. eiect will impose an equivalent variable rate or flow on the contents of the processing zone all the way back to initial mixing chamber l2 (Fig. 14).

ADVANTAGES Considering the manner of generating the substantially ashfree fuel gas as described above, including carburetting and superheating lit if desired, it will be evident that a new method of fuel gas generation is involved apart from any particular structure in which the fuel gas may be made, treated, used, or subjected to methods and means for heat recovery. Since heat for processing is added as fast as it is absorbed in raising temperatures of ingredients and bringing about the fuel gas reaction, the process is continuous. Among a number of other advantages are:

y Low cost of operation, eincient use of fuel both for the process and heat supply so that a maximum of available energy is utilized, improved heating of ingredients and the precipitation, co1- lection and ejection of' ash is accomplished. Moreover, the described embodiment of my invention requires for the most part only standard equipment and materials readily obtained in the market and is easily built. Once the process is begun there need oe-no interruption "for a considerable time. The deliveries of the various feeders and the air supply may be accurately predetermined after tests, and once the apparatus is set little attention will be necessary. For variable product demands, interconnecting conm trol 'mechanisms are available in the open market.

COUNTERFLOW yRegarding the relative directions of the streams in the heating zone and the processing zone, a parallel :fioul apparatus is illustrated by drawings or Figs. 1-10 and it-17. lioweer, the apparatus can be designed to voperate on the principle'of counterflow, particularly when used as a gas generator. By this I meanthatthf-z'v fresh Little or no backpressure' chamber in its middle.

relatively cool ingredients entering the processing zone are heated by the gases of the heating zone at a point just before these latter pass out o'f the system, and as the processing zone ingredients grow progressively hotter, they encounter hotter portions of the heating zone. This is practicable, and has certain advantages in that the fuel gas leaving the furnace is subjected to the highest heat, thus elfecting the reaction of any unconverted solids and the fresh cool ingredients entering the furnace stillextract the maximum heat from the somewhat cooled gases of the heating zone. Examples of apparatus operating on the principle of counterflow are shown in Figs. 20-23 described below. Methods and structural elements disclosed above in connection with parallel flow, in general apply equally well to the apparatus operating in counterflow, which I will now describe.

Products of combustion of fuel or other hot gases enter the heating zone through port |01 shown in Fig. 2O passing under a vertical bafe |98 normal to the general direction of flow, and then through tubes |69 to chamber im. From H0 the gases pass under a vertical baiile Ia (perpendicular to baffle |28) to tubes and enter chamber H2; from chamber ||2 the gases go under baffle |081; (perpendicular to baffle loto) to and through tubes H3 to disposal chamber H4. Valve or door H5 controls access to space lli for mixing the products of zones when desired as hereinafter described. When such mixing is not desired the valve H5 will be closed and discharge from the apparatusis through port Il'l. Due to passage of hot gases through tubes of tube nests |09, ||I and H3 shown also in Figs. 21, 22 and 23, the tube walls are heated. Thus the gases being processed in the processing zone, as they pass among these heated tubes, are supplied with the heat necessary for the chemical reaction to be eiected` Ingredients to be processed are delivered to the processing zone through feeder |20 into an initial mixing chamber 12|. In that chamber additional ingredients may be mixed in, said ingredients entering through valved openings |36, |31 and |38 shown in Fig. 23 adjacent the feeder |20.

The ingredients move downwardly and on reaching the bottom of space |2| the ingredients move through the horizontal leg of an L-shaped chamber |22 and rise through the vertical leg, passing among the first portion of tube nest H3 shown in Figs. 21 and 22. This tube nest is divided in two parts by a vertical partition ||3p In this first portion the gases absorb heat from the heated tube walls as de scribed in detail above.

Upon reaching the top of the iirst section of tube nest H3, the gases move horizontally over into passage |23. Passage |23 is. shaped similarly to passage 'IW-dll shown in Fig. 19, and connects with the bottom of a passage leading up among the second section ofthe tube nest H3. Thus the gases can pass down passage |23 and thence up through the second portion of tube nests H3 and horizontally into another passage |25. Passage |25 is similar to passage 82' of Fig. 19 and connects at its bottom with passage |26 2l and 22). Thus the gases move down passage |25 and horizontally overk through passage vitil ig.- 22) and are then able to move up among the first portion of the second tubenest lli to emerge in the chamber |21. The struc.- ture of the passages |2l--l3l inclusive is idenfa cooler chamber and Yleading 7. A '-iiiethod :for removing `l'ent-rainedparticles Yfrom thegcolder Nof two hot, f'uidizeelpowder fstrea-'ms A`of unequal temperatures which @comprises leading Athe -colder stream through Ia )plurality of connected units, in of which 4the colder stream is -led #rs/tfu'pwardly through 'la Vheated chamber and-then Adownwardly through the hotterstream through heat-transfer l` means fadapteclyitc heat 'the -heated chamber in each of said j moves from a cooler lchamber to a heated chamber and the decrease "in velocity'of the streamvin the'cooler chamber causingnfportion of fthe lens, ythe 'reversal of direction -ofowafss'aid colder-stream trained dust to precipitate'vfrm said ""c'older stream.

8. An apparatus for v'proces'sing gaseous and fluidized powder reactant Astreamscomprising a heatingenclosure for generatin'g'a moving'fstream of hot gaseous products of combustion fand 1a processing enclosure for subjecting the gaseous and fiuidized powder stream to be processed to the heat developed in said heating enclosure, said heating enclosure including a combustion chamber, means for charging fuel to said combustion chamber, a disposal chamber and connecting means, comprising a plurality of tubes joining said combustion chamber to said disposal chamber whereby h-ot gaseous matter originating from the combustion of fuel in said combustion chamber may be carried through said connecting tubes, heating said connecting tubes, and passed to said disposal chamber, and said processing enclosure including a mixing chamber for mixing reactants to be processed and at least one processing unit, said unit comprising a rst chami ber and a second chamber, said rst chamber 'being connected at its top to the top of the second chamber, said rst chamber enclosing a portion of the heated tubes of the heating enclosure to add heat to said rst chamber and said second chamber being removed from said tubes and cooler than the gases coming from said rst chamber, and means connecting the bottom of said mixing chamber to the bottom of said rst chamber, said heated tubes in said rst chamber being above the connection of said first chamber with said mixing chamber, whereby the reactants mixed in said mixing chamber are caused to flow by thermosyphonic forces generated in said units past the tubes of said heating enclosure and are thereby raised to reaction temperature.

9. An apparatus as in claim 8 having means to collect precipitated solids from the reactant stream comprising hoppers formed in the lower portions of those chambers in the processing enclosure in which the stream ilows downwardly.

l0. An apparatus as in claim 8 wherein said tubes are inclined from the horizontal to facilitate the shedding of solid particles deposited on the interior and exterior surfaces of the tubes and to increase the effective heating surface in the rst chamber of the processing enclosure.

11. An apparatus as in claim 8, wherein the means connecting the combustion and disposal chambers comprises a plurality of chambers, said plurality of chambers being connected, to each other serially by said tubes arranged in tube nests, and the rst of said plurality of chambers being connected to the combustion chamber, and

me last to 'ferie dissesti @chamber py nests, "and einem tube nests.

1.2. An apparatus asfissia@ 'ren-t its the fdireeticn :of new the heatirfg essere.

-13. :An apparatus s 14. gapparatus "as claiined claimli vrwherein the heating enclosurecinprss-arst combustion chamber, a disposal chamber and .afpl-urality f `intermediate vch'ajrribers arranged'i-in 'series nnected by tubular connecting means, said first combustion chamber being connected with the first of said series of intermediate chambers by tubular connecting means and said disposal chamber being connected with the last of said series of intermediate chambers by tubular connecting means, and wherein the heating enclosure also comprises a second combustion chamber connected by tubular connecting means with an intermediate chamber other than the one with which said rst combustion chamber is connected, whereby hot gaseous products of combustion produced in said second combustion chamber may be added to the material originating in said rst combustion chamber to compensate for heat absorbed from said material.

15. An apparatus as in claim 8 and including a steam boiler wherein the disposal chamber of the heating enclosure is the combustion chamber of said steam boiler whereby gases from said heating enclosure may be used for heating the steam boiler.

16. An apparatus for processing gaseous and uidized powder reactant streams, comprising a heating enclosure for generating a moving stream of hot gaseous products of combustion and a processing enclosure for subjecting the gaseous and luidized powder stream to be processed to the heat developed in said heating enclosure, said heating enclosure including a primary combustion compartment, a secondary combustion compartment, means for charging fuel to said primary combustion compartment, means for supplying air to said secondary combustion compartment, a plurality of tubes connecting said primary combustion compartment with said secondary combustion compartment, a disposal chamber and means comprising a plurality of tubes connecting said secondary combustion compartment with said disposal chamber whereby fuel may be partly burned in said primary combustion compartment, the hot products of primary combustion carried to said secondary combustion compartment for the completion of burning, and the hot products of combustion carried from said secondary combustion compartment to said disposal chamber, and said processing enclosure including a mixing chamber for mixing reactants to be processed and at least one processing unit, said unit comprising a 19 rst chamber and a secondl chamber, said first chamber being connected at its top to the top of the second chamber, said rst chamber enclosing the tubes connecting said primary com- -buston compartment with said secondary combustion compartment to add heat to said rst chamber, and said second chamber being removed from said tubes and cooler than the gases coming from said rst chamber, and means connecting the bottom of said mixing chamber to the bottom of said first chamber, said heated tubes in said first chamber being above the connection of said rst chamber with said mixing chamber, whereby the reactants mixed in said mixing chamber are caused to iiow by thermosyphonic forces generated in said unit past the tubes joining said primary combustion compartment to said secondary combustion compartment, and are thereby raised in temperature.

CARSTEN INGEMAN JOHNSEN.

References Cited in the file of this patent UNITED STATES PATENTS Number 2o Number Name Date 1,496,757 Lewis et al June 3, 1924 1,616,409 Bird Feb. 1, 1927 1,755,373 Soderlund et a1 Apr. 22, 1930 1,799,858 Miller Apr. 7, 1931 1,821,842 Long Sept. 1, 1931 1,941,809 McKee Jan. 2, 1934 1,984,380 Odell Dec. 18, 1934 2,081,406 Mozza May 25, 1937 2,113,774 Schmafeldt Apr. 12, 1938 2,268,134 Clusius Dec. 30, 1941 2,311,140 Totzek et al Feb. 16, 1943 2,451,804 Campbell et a1 Oct. 19, 1948 2,461,021 Atwell Feb. 8, 1949 2,478,295 Marecaux Aug. 9, 1949 FOREIGN PATENTS Number Country Date Great Britain July 21, 1921 OTHER REFERENCES Publication, Bourcoud, Chemical and Metallurgicai Engineering, vol. 24, No. 14, pages 600- 604 (1921). 

